Mercedes-Benz S-class W140 - Repair manual and operation

4. Engine

Specifications

General parameters

Separate characteristics are provided also in the text of the Head and in case of obligation of their performance are highlighted in bold type.

Engine

Specifications were defined according to directives of the EU. All data are valid for cars in basic execution with the catalytic converter. Depending on elements of a special complete set data can differ from each other. On this matter you can receive references on any HUNDRED Mercedes-Benzs.

General characteristics

Model	Years of the issue.	Code on VIN	Type of an engine/fuel supply system	Volume, cm3	Quantity and расп. c ditch	Power, hp/kW	Torque, Nanometer	Max. speed, km/h	Notes
300SE 2.8	92-93	140.028	M104.944HFM	2799	R6	193/142	270	215
S280	93-94
300SE (SEL)	91-93	140.032 (033)	M104.990LH	3199	R6	231/170	315	225
S320	93-98		M104.944HFM
300SD	91-93	140.134	OM603.971	3449	R6	150/110	330	185
S350 TD	93-96
S300 TD	96-98	140.135	OM606.961	2996	R6	177/130	330	205
400SE (SEL)	91-93	140.042 (043)	M119.971LH and M119.981ME	4196	V8	279/205	400	245
S420	93-98
500SE (SEL)	91-93	140.050 (051)	M119.970LH and M119.980ME	4973	V8	320/235	470	250	Ogr. 270 km/h
S500	93-98
600SE (SEL)	91-93	140.056 (057)	M120.980LH and M120.982ME	5987	V12	394/290	570	250	Ogr. 290 km/h
S600	93-98

Rated power, kW (h.p.) / at rpm)//Nominal torque, Nanometer (at rpm)
S280	142 (193)/5500//270/3750
S320	170 (231)/5600//315/3750
S420	205 (279)/5700//400/3900
S300	TDI 130/4400//330/1600-3600
S500	235 (320)/5600//470/3900
S600	290 (394)/5200//570/3800
Number cylinders/type/worker volume, cm3/designation
S280	6/DOHC/2799/104
S320	6/DOHC/3199/104
S420	8/OHC/4196/119
S300	TDI 6/DOHC/2996/606
S500	8/OHC/4973/119
S600	12/OHC/5987/120
Maximum turns, rpm
S280	6400
S320	6400
S420	6000
S300	TDI 5300
S500	6000
S600	6000
Extent of compression
S280	Data are not provided
S320	10.0:1
S420, S500	11.0:1
S600	Data are not provided
S320CDI	Data are not provided
Pressure of a compression, bar
S280 S320	10-14
S420, S500, S600	13.5-15.5
S300	TDI 26-32
Operating procedure of cylinders
S280, S320, S300	TDI 1-5-3-6-2-4
S420, S500	1-5-4-8-6-3-7-2
S600	1-12-5-8-3-10-6-7-2-11-4-9

Driving belt

(Generator/helmsman amplifier, air conditioner), mm
S280	2170/2257
S320	2337/2440
S420, S500	2460/-
S300	TDI 6PKx2080/6PKx2120
S600	2585/-
Valvate gaps	are not regulated since. hydrocompensators are used

Capital repairs of the engine

M104 series engines

Sizes of bearings of camshafts

Nominal diameter, mm
Camshaft	29.947 29.963
Head of the block of cylinders	30.000 30.021
Repair diameter, mm
Camshaft	30.434 30.450
Head of the block of cylinders	30.500 30.525.
Admissible purity of a surface of a bed, mm	0.001-0.004
Admissible conicity, mm	0.012
Admissible shift of an axis, mm	0.040
Side play in the bearing, mm
Radial	0.035
Axial	0.06 - 0.21

The sizes of the directing plugs of valves

Plugs from non-ferrous metal

The directing plug from non-ferrous metal (M104.990 engines of the first version)

Diameters of openings in a head of the block of cylinders, mm
Nominal size	13.50-13.51
1st nominal size	13:53
Repair size	13.70
Outer diameter of the directing plug, mm / Color marking
Nominal size	13.52-13.53/-
1st nominal size	13.54-13.55/Gray-brown
Repair size	13.71-13.72 / Red
Tightness, mm	0.012-0.031
Internal diameter of the directing 1st version, mm
Inlet valve	8.000-8.015
Final valve	9.000-9.015
Internal diameter of the directing 2nd version, mm
Inlet valve	7.000-7.015
Final valve	8.000-8.015
Length of the "L" plug, mm
Inlet valve	35.5
Final valve	37.9
Vystupaniye "from" the plug, mm
Inlet valve	10.8-11.2
Final valve	8.2-8.6

Ceramic-metal plugs

The metal directing plug of the M104.990 engine (the second version) and M104.944/994

Diameter of an opening in a head of the block of cylinders, mm
Nominal size	12.50-12.51
1st nominal size	12:53
Repair size	12.70
Outer diameter of the directing plug, mm / Color marking
Nominal size	12.54/-
1st nominal size	12.56-12.57/-
Repair size	12.74-12.75/-
Tightness, mm	0.029-0.051
Internal diameter of the directing plug, mm
Inlet and final valves	7.000-7.015
Length of the "L" guide of the plug, mm
Inlet and final valves	37.5
Vystupaniye "from" the directing plug, mm
Inlet and final valves	10.2-10.4

Sizes of saddles of valves

Details of installation of saddles of valves

Inlet valve//Final valve
Nominal rates, mm
Diameter of D1 of an opening	36 H6//32 H6
Diameter is D a saddle	36.10-36.12/32.10-32.12
Repair values, mm
Diameter of D1 of an opening	37.20 H6 H6//33.20
Diameter is D a saddle	37.30/32.30
T size	5.6-5.9
Diameter of D2	30/25.6

Performance data of piston rings

Gaps of landing of rings in flutes of pistons, mm
Characteristic	Value
Top compression ring	0.20-0.40
Lower compression ring	0.20-0.40
Oil scraper ring	0.20-0.45
Gaps in locks of rings, mm
Top compression ring	0.015-0.050
Lower compression ring	0.020-0.040
Oil scraper ring	0.010-0.045

Sizes and weight of rods and conrod bearings

2 — Designation 3 — the Balancing small weight 4 — M9 Bolt 5 — the Directing plug	6 — the Top insert 7 — Nizhny Novgorod an insert 8 — Adjusting ears Arrow — the Direction of the movement

Rods
Distance of "L" between centers heads of a rod, mm
M104.94	148.995-49.005
M104.99	144.995-145.005
Width "In" lower heads of a rod, mm	21.948 - 22.000
Width of "b" of the top head of a rod, mm	21.948 - 22.000
Diameter of "D1" of the lower head without inserts, mm	51.600 - 51.619
Diameter of "d1" of the top head under the plug, mm	24.500 - 24.571
Internal diameter of "d" of the plug of the top head of a rod, mm	22.007 - 22.013
Side play of a piston finger in the plug, mm	0.013 - 0.018
Admissible twisting of a rod, mm	0.015
Tolerance from parallelism top head of a rod and plug, mm	0.07
Admissible difference of scales of rods,	4
Bent shaft
Diameters of conrod necks, mm / color marking of a cheek of a crank
Nominal	47.955 - 47.965 / Not marked
Nominal	1 47.945 - 47.955 / Orange
Nominal	2 47.935 - 47.945 / Blue
1st repair size	47.700 - 47.715/-
2nd repair size	47.450 - 47.465/-
3rd repair size	47.200 - 47.215/-
4th repair size	46.950 - 46.965/-
Width of conrod necks, mm
Nominal size	27.958 - 28.042
Repair size	to 28.300
Inserts of conrod bearings
Thickness of a wall, mm
Nominal size
Red marking	1.806 - 1.810
Yellow marking	1.810 - 1.814
Blue marking	1.814 - 1.818
Nominal 1 (it is not delivered as the spare part)
Red marking	1.811 - 1.815
Yellow marking	1.815 - 1.819
Blue marking	1.819 - 1.823
Nominal 2 (it is not delivered as the spare part)
Red marking	1.816 - 1.820
Yellow marking	1.820 - 1.824
Blue marking	1.824 - 1.828
1st repair size (Yellow marking)	1.995 - 1.999
2nd repair size (Yellow marking)	2.060 - 2.064
3rd repair size (Yellow marking)	2.185 - 2.189
4th repair size (Yellow marking)	2.310 - 2.314

Sizes of a bent shaft and radical bearings

Control sizes
Admissible conicity of radical and conrod necks of a bent shaft, mm	0.002
Admissible ovality on 54 mm of length, mm
Radical necks	0.010
Conrod necks	0.010
Tolerance of an axis of the established inserts, mm	0.02
Radius of an internal galtela, mm
Radical necks 1.9-2.1
Conrod necks 1.9-2.1
Repair sizes
Diameter of a radical neck, mm / Color/alphabetic marking on a forward part of a bent shaft
Nominal
57.960 - 57.965/Синий/В
57.955 - 57.960/Zhelty/G
57.950 - 57.955/Krasny/R
Nominal 1
57.945 - 57.950/Bely/W
57.940 - 57.845/Purpurny/V
1st repair size	57.705 - 57.715/-/-
2nd repair size	57.450 - 57.465/-/-
3rd repair size	57.205 - 57.215/-/-
4th repair size	57.955 - 57.965/-/-

Alphabetic marking

Color marking is applied on counterbalances No. No. 8 and 9, alphabetic reference - on a forward part of a bent shaft.

Width of a radical neck, mm / Color /
Nominal size
24.500 - 24.533/-/0
Nominal 1
24.600 - 24.633/Krasny/1
1st repair size	24.700 - 24.733/-/-
2nd repair size	24.900 - 24.933/-/-
3rd repair size	25.000 - 25.033/-/-
4th repair size	-/-/-

Selection of thickness of inserts of radical bearings

The nominal size (Diameter of an opening under a neck of the radical bearing of 58.00 mm)
Blue tag (index 52)
Thickness of the top insert, mm	2.255-2.260
Thickness of the lower insert, mm	2.255-2.260
Yellow tag (index 54)
Thickness of the top insert, mm	2.260-2.265
Thickness of the lower insert, mm	2.260-2.265
Red tag (index 56)
Thickness of the top insert, mm	2.265-2.270
Thickness of the lower insert, mm	2.265-2.270
The nominal size 1 (Diameter of an opening under a neck of the radical bearing of 58.00 mm)
White-blue tag (index 57)
Thickness of the top insert, mm	—
Thickness of the lower insert, mm	2.263-2.268
White-yellow tag (index 58)
Thickness of the top insert, mm	—
Thickness of the lower insert, mm	2.268-2.273
White-red tag (index 60)
Thickness of the top insert, mm	—
Thickness of the lower insert, mm	2.273-2.278
The 1st repair size (Diameter of an opening under a neck of the radical bearing of 57.75 mm)
Blue tag (index 52)
Thickness of the top insert, mm	2.375-2.380
Thickness of the lower insert, mm	2.375-2.380
Yellow tag (index 54)
Thickness of the top insert, mm	2.380-2.385
Thickness of the lower insert, mm	2.380-2.385
The 2nd repair size (Diameter of an opening under a neck of the radical bearing of 57.50 mm)
Blue tag (index 52)
Thickness of the top insert, mm	2.500-2.505
Thickness of the lower insert, mm	2.500-2.505
Nominal width of an insert, mm	19.979 - 20.000
Diameter of beds of radical bearings of a bent shaft, mm
Bearings No. No. 1, 5, 7
1 kerneniye	62.500-62.505
2 kerneniye	62.506-62.513
3 kerneniye	62.513-62.519
Bearings No. No. 2, 3, 4, 6
2 kerneniye	62.500-62.506
3 kerneniye	62.506-62.519

Sizes and designations of cylinders and pistons

Diameters of cylinders//pistons, mm
Nominal size (89.9 mm)
Marking of group of the admission of A	89.900 - 89.906/89.873 - - 89.879
Marking of group of the admission of X	89.906 - 89.912/88.878 - - 89.886
Marking of group of the admission In	89.912 - 89.918/89.885 - - 89.891
1st repair size (+ 0.25 mm)
Marking of group of the admission of A	90.150 - 90.156/90.123 - - 90.129
Marking of group of the admission of X	90.156 - 90.162/90.128 - - 90.136
Marking of group of the admission In	90.162 - 90.168/90.135 - - 90.141
2nd repair size (+ 0.5 mm)
Marking of group of the admission of A	90.400 - 90.406/90.373 - - 90.379
Marking of group of the admission of X	90.406 - 90.412/90.378 - - 90.386
Marking of group of the admission of B	90.412 - 90.418/90.385 - - 90.391

Marking (except AMG engines) is put on a convex part of the piston and beaten out on the interfaced surface of the block of cylinders.

Sizes of the block of cylinders

Height, mm	282.25 - 282.35
Minimum admissible height after obrabotki1), mm	281.95
Admissible roughness of the interfaced surface of the block of cylinders, mm
Top	0.03
Lower	0.04
1) After processing of the block of cylinders change of height no more than on 0.4 mm is allowed.

M119 series engines

Sizes of bearings of camshafts

Diameter of beds of bearings of camshafts in a head of the block of cylinders, mm
Nominal size	28.000 28.021
Repair size	28.500 26.521
Diameter of a neck of the bearing of the camshaft, mm
Nominal	27.960 2.947
Repair	28.447 28.460
Side play in bearings of the camshaft, mm
Radial	0.053-0.061
Axial	0.050-0.150

The sizes of the directing plugs of valves

The directing plug from non-ferrous metal (M104.990 engines of the first version)

Plugs from non-ferrous metal (only M119.97 engines)
Diameters of openings in a head of the block of cylinders, mm
Nominal size	13.50-13.51
1st nominal size	13:53
Repair size	13.70
Outer diameter of the directing plug, mm / color marking
Nominal size	13.51-13.53/-
1st nominal size
	13.52-13.53/is gray-green
	13.54-13.55/is gray-brown
Repair size	13.71-13.72 / Red
Outer diameter of the directing plug, mm / color marking
Internal diameter of a guide, mm
Inlet and final valves	7.000-7.015
Outer diameter of the directing plug, mm / color marking
Length of the "L" plug, mm
Inlet valve	35.5
Final valve	37.9
Distance "and" (inlet valve), mm	2.7-2.9
Distance of "b" (inlet and final valves), mm	5.4-5.6
Distance "with" (inlet and final valves), mm	10.8-11.2
Ceramic-metal plugs (all engines of the M119 series)
Diameter of an opening in a head of the block of cylinders, mm
Nominal size	12.50-12.51
1st nominal size	12:53
Repair size	12.70
Outer diameter of the directing plug, mm / Color marking
Nominal size	12.54-12.55/-
1st nominal size	12.56-12.57 / Grey
Repair size	12.74-12.75 / Red
Internal diameter of the directing plug, mm
Inlet and final valves	7.000-7.015
Length of the "L" guide of the plug, mm
Inlet and final valves	37.5
Distance "and", mm	—
Distance of "b" (inlet and final valves), mm	5.4-5.6
Distance "with" (inlet and final valves), mm	10.2-10.4

Sizes of saddles of valves

M119.970 engines

Nominal sizes
Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves	39 H6
Final valve	34 H6
Diameter of the "D" saddle, mm
Inlet valves	39.10-39.09
Final valves	34.10-34.09
Repair sizes
Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves	40.20 H6
Final valves	35.20 H6
Diameter of the "D" saddle, mm
Inlet valves	40.30
Vypuseny valves	35.30
T size (inlet and final valves), mm	7.8-7.9
Diameter of "D2", mm
Inlet valves	38.47
Final valves	33.47

M119.971/980/982 engines

Nominal sizes
Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves	36 H6
Final valves	34 H6
Diameter of the "D" saddle, mm
Inlet valves	36.10-36.09
Final valves	34.10-34.09
Repair sizes
Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves	37.20 H6
Final valves	35.20 H6
Diameter of the "D" saddle, mm
Inlet valves	37.30
Final valves	35.30
T size (inlet and final valves), mm	7.8 - 7.9
Diameter of "D2", mm
Inlet valves	35.47
Final valves	33.47

Sizes and designations of cylinders and pistons

A — the Longitudinal direction B — the Cross direction and — the Top point of the course of the top compression ring	b — the Lower dead point with — the Lower point of the course of an oil scraper ring 1, 2, 3 — Points of measurements

Engines of the M119.960/970/972/974 series

Diameters of pistons//cylinders, mm
Nominal size (96.5 mm)
Designation 0 (index 52)	96.483-96.493/96.498-96.503
Designation 0+ (Index 53)	96.488-96.498/96.503-96.508
Designation 1 (Index 54)	96.493-96.503/96.508-96.513
Designation 1+ (Index 55)	96.498-96.508/96.513-96.518
Designation 2 (Index 56)	96.503-96.513/96.518-96.523
1st repair size (+0.5 mm)
Designation 0	96.983-96.993/96.998-97.003
Designation 1	96.993-97.003/97.008-97.013
Designation 2	97.003-97.013/97.018-97.023
The 2nd repair (+1.0 mm)
Designation 0	97.483-97.493/97.498-97.503
Designation 1	97.493-97.503/97.508-97.513
Designation 2	97.503-97.513/97.518-97.523

Engines of the M119.980/982/970/972/974 series

Diameters of pistons//cylinders, mm
Nominal size (96.5 mm)
Designation A (index 52)	96.482-96.495/96.500-96.508
Designation B (index 54)	96.491-96.504/96.508-96.516
Designation C (index 56)	96.499-96.512/96.516-96 524
The 1st repair (+0.5 mm)
Designation A	96.982-96.995/97.000-97.008
Designation B	96.991-97.004/97.008-97.016
Designation	With 96.999-97.012//97.016-97.024
The 2nd repair (+1.0 mm)
Designation A	97.482-97.495/97.000-97.508
Designation B	97.491-97.504/97.508-97.516
Designation C	97.499-97.512/97.516-97.524

M119.971/975/981/985 engines (digital designation)

Diameters of pistons//cylinders, mm
Nominal size (92.0 mm)
Designation 0 (index 52)	91.983-91.993/91.998-91.003
Designation 0+ (index 53)	91.988-91.998/92.003-92.008
Designation 1 (index 54)	91.993-92.003/92.008-92.013
Designation 1+ (index 55)	91.998-92.008/92.013-92.018
Designation 2 (index 56)	92.003-92:013/92.018-92.023
The 1st repair (+0.5 mm)
Designation 0	92.483-92.493/92.498-92.503
Designation 1	92.493-92.503/92.508-92.513
Designation 2	92.503-92.513/92.518-92.523
The 2nd repair (+1.0 mm)
Designation 0	92.983-92.993/92.998-93.003
Designation 1	92.993-93.003/93.008-93.013
Designation 2	93.003-93.013/93.018-93.023

M119.971/975/981/985 engines (alphabetic reference)

Diameters of pistons//cylinders, mm
Nominal size (96.5 mm)
Designation A (index 52)	91.982-91.995/92.000-92.008
Designation B (index 54)	91.991-92.004/92.008-92.016
Designation C (index 56)	91.999-92.012/92.016-92.024
The 1st repair (+0.5 mm)
Designation A	92.482-92.495/92.500-92.508
Designation B	92.491-92.504/92.508-92.516
Designation C	92.499-92.512/92.516-92.524
The 2nd repair (+1.0 mm)
Designation A	92.982-92.995/93.000-93.008
Designation B	92.991-93.004/93.008-93.016
Designation C	92.999-93.012/93.016-93.024

Sizes of rods

Rods

Distance of "L" between centers heads of a rod, mm	154.450-154.550/148.950-149.050
Width "In" lower heads of a rod, mm	24.857-24.890/24.857-24.890
Width of "b" of the top head of a rod, mm	27.900-28.000/21.900-22.100
Diameter of the "D" lower head without inserts, mm	51.600-51.619/51.600-51.619
Diameter of "d1" of the top head under the plug, mm	26.007-26.013/24.007-24.013
Internal diameter of "d" of the plug of the top head rod, mm	29.000-29.021/27.000-27.210
Side play of a piston finger in the plug, mm	0.007-0.018

Sizes of a bent shaft, radical and conrod bearings

Engines with the adjusting bearing

Diameter of a neck of a bent shaft, mm
Nominal
Blue marking	63.965
Yellow marking	63.960
Red marking	63.955
The 1st repair	63.700
2nd repair size	63.450
3rd repair size	63.200
4th repair size	62.950
Width of a radical neck with the adjusting bearing, mm
Nominal size	27.021
Extreme admissible size	27.50
Diameter of a neck of a bent shaft, mm
Nominal	47.955
The 1st repair	47.705
2nd repair size	47.455
3rd repair size	47.205
4th repair size	46.955
Width of a radical neck, mm
Nominal size	50.100
Extreme admissible size	50.30
Diameter of openings under radical bearings, mm
Blue marking	68.486
Yellow marking	68.492
Red marking	68.500
Diameter of openings under conrod bearings, mm	51.619
Admissible ovality and conicity of radical and conrod necks of a bent shaft, mm	0.01
Radial gap in radical bearings, mm
New shaft	0.021 - 0.045
Maximum permissible value	0.09
Radial gap in conrod bearings, mm
New shaft	0.030 - 0.055
Maximum permissible value	0.080
Axial side play of a bent shaft, mm
New shaft	0.10 - 0.22
Maximum permissible value	0.30
Axial side play of rods, mm
New shaft	0.22 - 0.38
Maximum permissible value	0.50

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters	Marking
Pointed marking on the block of cylinders	1 point	2 points	3 points
Color marking on covers подшип-ников / casting of the block	Blue	Yellow	Red
Color marking of the top inserts	Blue	Yellow	Red
Color marking of the lower inserts	Blue	Yellow	Red

Engines with persistent half rings

Diameter of a neck of a bent shaft/thickness of persistent half rings, mm
Nominal size
Blue marking	63.960-63.965/2.20
Yellow marking	63.955-63.960/2.25
Red marking	63.950-63.955/2.30
1st nominal size	63.945-63.950 63.940-63.945 63.935-63.940
Width of a neck of a bent shaft, mm	27.000-27.033
Diameter of a neck of a bent shaft, mm	47.955-47.965
Width of a neck of a bent shaft, mm	50.000/50.100
Diameter of openings under radical bearings, mm
Blue marking	68.480-68.486
Yellow marking	68.986-68.492
Red marking	68.492-68.500
Diameter of openings under conrod bearings, mm	51.600-51.619
Admissible ovality and conicity of radical and conrod necks of a bent shaft, mm	0.01
Radial gap in radical bearings, mm
New shaft	0.021 - 0.045
Maximum permissible value	0.09
Radial gap in conrod bearings, mm
New shaft	0.030 - 0.055
Maximum permissible value	0.080
Axial side play of a bent shaft, mm
New shaft	0.10 - 0.22
Maximum permissible value	0.30
Axial side play of rods, mm
New shaft	0.22 - 0.38
Maximum permissible value	0.50

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters	Marking
Pointed marking on the block of cylinders	1 point	2 points	3 points
Color marking on covers подшип-ников / casting of the block	Blue	Yellow	Red
Color marking of the top inserts	Blue	Yellow	Red
Color marking of the lower inserts	Blue	Yellow	Red

M120 series engines

Code designations of camshafts

Engines of the M120.980 series on No. 010 822
Right inlet camshaft	29
Left inlet camshaft	30
Right final camshaft	27
Left final camshaft	28
Engines of the M120.980 series with No. 010 823 and M120.982
Right inlet camshaft	33
Left inlet camshaft	34
Right final camshaft	31
Left final camshaft	32

The sizes and details of installation of the directing plugs of valves

Details of installation of the directing plugs of valves

Plugs from non-ferrous metal
Internal diameter of the directing plug, mm
Inlet valve	7.000 - 7.015
Final valve	8.000 - 8.015
Length of the directing L plug, mm	37.5
Tightness in a head of the block of cylinders	0.029 - 0.051
Lock ring	It is not established
Distance of "a"	2.7 - 2.9
Distance of "b"	5.4 - 5.6
Distance "with"	8.2 - 8.6
The metallized plugs
Internal diameter of the directing plug, mm
Inlet valve	7.000 - 7.015
Final valve	7.000 - 7.015
Length of the directing L plug, mm	37.5
Tightness in a head of the block of cylinders	0.029 - 0.051
Lock ring	It is established
Distance of "a"	—
Distance of "b"	—
Distance "with"	10.2 - 10.4

Sizes and designations of cylinders and pistons

Diameters of cylinders//pistons, mm
Nominal size (89 mm)
Gruppa1) 0	89.000 - 89.008/88.978 - - 88.988
Group 1	89.008 - 89.016/88.988 - - 88.998
Group 2	89.016 - 89.024/88.998 - - 89.008
1st repair size (+ 0.352) mm)
Group 0	89.350 - 89.358 / 89.328 - - 89.338
Group 1	89.358 - 89.366 / 89.338 - - 89.348
Group 2	89.361 - 89.374 / 89.348 - - 89.358
2nd repair size (+0.72) mm)
Group 0	89.700 - 89.708 / 89.678 - - 89.688
Group 1	89.708 - 89.710 / 89.688 - - 89.698
Group 2	89.716 - 89.724 / 89.698 - - 89.708
1) Number of group on new engines is beaten out on the interfaced surface of the block of cylinders, the following cylinder
2) Number of group is put on a piston skirt with paint and, besides, is beaten out sideways on a piston skirt

Sizes of rods

L size, mm	153.95 - 154.05
Width of the lower conrod head "In", mm	21.948 - 22.000
Width of the top conrod head of "b", mm	19.90 - 20:10
Diameter of an opening of the lower head of a rod of "D1", mm	51.600 - 51.619
Diameter of an opening of the top head of a rod of "d1", mm	24.500 - 24.521
Internal diameter of the plug of the top head of a rod of "d", mm	22.007 - 22.013
Gap of landing of a piston finger in the plug of a rod, mm	0.013 - 0.018
Admissible difference of scales of rods assembled,	4

Sizes of a bent shaft, radical and conrod bearings

Diameter of a radical neck of a bent shaft/thickness of persistent laying of the adjusting bearing, mm
Nominal size	57.960/2.15 57.955/2.20 57.950/2.25
1st nominal size	57.945/2.35 57.940/2.40 57.935
1st repair size	57.700
2nd repair size	57.450
3rd repair size	57.200
Diameter of conrod necks, mm
Nominal size	47.955
1st repair size	47.705
2nd repair size	47.455
3rd repair size	47.205
Width of conrod necks, mm	24.225
Diameter of beds of radical bearings, mm	62.500
Diameter of beds of conrod bearings, mm	61.600
Internal diameter of radical bearings, mm	23.500
Width of a conrod neck, mm	22.000
Admissible ovality and conicity of beds of bearings	0.02
Radial gap, mm
Radical bearings	0.026 - 0.050
Conrod bearings	0.020 - 0.058
Axial side play of a bent shaft, mm	0.100 - 0.254
Axial side play of rods, mm	0.225 - 0.391

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters	Value
Pointed marking on the block of cylinders	1 point	2 points	3 points	—	—
Color marking on covers of bearings	Blue	Yellow	Red	—	—
Color marking on a bent shaft	Blue	Yellow	Red	White	Violet
Color marking of the top inserts	Blue	Yellow	Red	—	—
Color marking of the lower inserts	Blue	Yellow	Red	White	Violet
Alphabetic marking on necks of radical bearings	In	G	R	W	V
The valid numbers of diameters on radical necks	35-39	40-44	45-49	50-54	55-60

OM603 series engines

Sizes of rods

1 — the Rod 2 — the Conrod cover 3 — the Plug 4 — the Directing grooves 5 — the Conrod bolt 6 — Balancing small weights 7 — the Identification field (models with a turbo-supercharging) 8 — Grooves for installation of inserts 9 — the Oil channel (models with a turbo-supercharging)

10 — the Oil channel (models without turbo-supercharging) 11 — the Identification field (models without turbo-supercharging) b — Width of the top head of a rod B — Width of the lower head of a rod d — the Internal diameter of the plug of the top head of a rod d1 — the Outer diameter of the plug of the top head of a rod D1 — Diameter of an opening of the lower head of a rod L — distance between centers openings of heads of a rod

L size, mm	144.97 - 145.03
Width of the lower head of a rod "In", mm	21.948 - 22.000
Diameter of an opening of the lower head of a rod of "D1"	51.600 - 51.614
Maximum admissible ovality and conicity of an opening, mm	0.02
Internal diameter of the plug of the top head of a rod of "d", mm	28.018 - 28.024
Outer diameter of the plug, mm	30.575 - 30.600
Diameter of an opening of the top head of a rod (under the plug) "d1", mm	30-500 - 30-525
Side play of landing of a piston finger in the plug of a rod, mm	0.007 - 0.018

Sizes of cylinders

Diameter of cylinders, mm
Nominal	89.0
Dimensional group A	89.000 - 89.006
Dimensional group X	89.007 - 89.012
Dimensional group B	89.013 - 89.018
Tolerance of diameter of the cylinder in the longitudinal and cross directions, mm	0.20
Admissible conicity, mm	0.007
Admissible ovality, mm	0.07
Limit of wear, mm	0.05

The sizes of openings in the block of cylinders under installation of sleeves

D, D1 — Diameters under sleeve fillets D2 — Diameter under a sleeve T — sleeve Length T1 — the Landing depth of a sleeve

Diameter of "D2" under a sleeve in the block cylinders, mm	91.500 - 91.535
Diameter of "D1" under a sleeve fillet in the block of cylinders, mm	92.00 - 92.20
Diameter "D" under fillet sleeves in the block of cylinders, mm	94.15 - 94.25
Length of a sleeve of "T", mm	231.0 - 231.2
Landing depth of a sleeve of "T1", mm	1.0 - 1.2
Width of a facet of "M", mm	35

Sizes of a bent shaft, radical and conrod bearings

Diameter of a radical neck, mm
Nominal size	57.940 - 57.965
1st repair size	57.700 - 57.715
2nd repair size	57.450 - 57.465
3rd repair size	57.200 - 57.215
4th repair size	56.950 - 56.965
Diameter of a radical neck, mm
Nominal size	47.940 - 47.965
1st repair size	47.700 - 47.715
2nd repair size	47.450 - 47.465
3rd repair size	47.200 - 47.215
4th repair size	46.950 - 46.964
Adjusting width of radical necks, mm
Nominal size	24.500 - 24.533
1st repair size	24.600 - 24.633
2nd repair size	24.700 - 24.733
3rd repair size	24.900 - 24.933
4th repair size	25.000 - 25.033
Diameter of an opening under a bent shaft, mm	62.500 - 62.519
Opening width under a bent shaft at the established inserts, mm	19.979 - 20.000
Admissible ovality and conicity of beds of inserts of radical bearings, mm	0.02
Working gaps of radical bearings, mm
New	0.03 - 0.05
Admissible	0.08
Axial side play of a bent shaft, mm
New	0.10 - 0.25
Admissible	0.3
Radial beating of a bent shaft, mm	0.020 - 0.065
Standard inserts of a bent shaft for covers of bearings diameter	58 mm
Repair diameter (color - blue), mm	52
Repair diameter (color yellow), mm	54
Repair diameter (color yellow), mm	54
Thickness of an insert, mm	2.260 - 2.265
Repair diameter (color - red), mm	56
Thickness of an insert, mm	2.265 - 2.270
Repair diameter (color white), mm	57
Thickness of an insert, mm	2.270 - 2.275
Repair diameter (color purple), mm	58
Thickness of an insert, mm	2.275 - 2.280

OM606 series engines

Sizes of valves

1 — Adjusting tags for reduction of the engine in the provision of VMT of the end of a step of compression of the piston of the first cylinder 2 — Blocking of the inlet camshaft by means of a core 3 — Make sure of correctness of combination of 1.5-millimeter openings in asterisks 4 — For fastening of asterisks of camshafts the disposable bolts which are subject to replacement without fail are used

5 — Assembly of a natyazhitel of a chain 6 — At the TNVD removal/installation the bent shaft should be given to situation 14 °+05 ° after VMT of the piston of the first cylinder 7 — the Bolt of an asterisk of TNVD has the left cutting. 8 — the Lock tool

Diameter of a plate of the D valve, mm
Inlet	25.90 - 26.10
Final	28.90 - 29.10
Height of a cylindrical part (corbel) plates of the h valve, mm	1.0 - 1.2
Valve saddle facet corner	45 ° 15'
Diameter of a core of the D1 valve, mm
Inlet	6.955 - 6.97
Final	5.955 - 5.97
Full is long the L valve, mm
Inlet	105.5 - 105.9
Final	105.2 - 105.9
Width of a working facet of a saddle of the valve, mm	1.9
Valve saddle axis shift concerning a core, mm	0.03
Designation on the end of a core of the valve
Inlet	A 606 13
Final	E 606 11

The sizes of the directing plugs of valves

Details of installation of the directing plugs of valves

Diameter of an opening in a head of the block of cylinders, mm
Nominal	12.50 - 12.51
The 1st nominal	12:53
The 1st repair	12.70
Outer diameter of the directing plug, mm
Nominal	12.54 - 12.55
The 1st nominal (color: gray)	12.56 - 12.57
The 1st repair (color: red)	12.74 - 12.75
Internal diameter of the directing plug, mm
Inlet valve	6.000 - 6.015
Final valve	6.000 - 6.015 (till 11.94) 7.000 - 7.015 (from 11.94)
Length of the directing L plug, mm	37.5
Landing tightness in a block head cylinders, mm	0.029 - 0.051
And size	—
B size	—
With the size	10.2 - 10:04

Sizes of saddles of valves

Milling and grinding of saddles of valves

Details of installation of a saddle of the valve

Internal diameter of the directing plug, mm
Width of a facet of a saddle of the b valve, mm
Inlet valve	1.0 - 1.5
Final valve	0.8 - 1.5
Valve saddle facet corner	45 ° 15'
Adjustment corner in
Inlet valve	15 ° 15'
Final valve	25 ° 15'
Extreme ovality of a saddle of the valve, mm	0.03
Distance from a valve core end face to the bearing of the camshaft "T", mm	23.7 - 24.2
Opening depth "With" under a valve saddle in a head of the block of cylinders, mm
Standard ring
Inlet valve	7.94 - 8.04
Final valve	7.924 - 8.02
Repair ring
Inlet valve	8.14 - 8:24
Final valve	8.12 - 8.23
Radius of "R", mm
Inlet valve	0.2 - 0.4
Final valve	0.2 - 0.4
Diameter of "D2" of an opening under a saddle of the valve, mm
Nominal size
Inlet valve	30.060 - 30.070
Final valve	28.000 - 28.013
Repair size
Inlet valve	30.250 - 30.266
Final valve	28.250 - 28.263
Overlapping of valves, mm
Inlet valve	0.2 - 0.4
Final valve	0.2 - 0.4
Height of a saddle of the valve "H", mm
Nominal size
Inlet valve	5.6
Final valve	5.6
1st repair size
Inlet valve	5.6
Final valve	5.6
Outer diameter of the "D" saddle of the valve, mm
Nominal size
Inlet valve	30.000 - 30.013
Final valve	27.97 - 28.07
1st repair size
Inlet valve	30.31 - 30.32
Final valve	28.31 - 28.32

Sizes of rods

1 — the Rod 2 — the Conrod cover 3 — the Plug 4 — the Directing grooves 5 — the Conrod bolt 6 — Balancing small weights 7 — the Identification field (models with a turbo-supercharging) 8 — Grooves for installation of inserts 9 — the Oil channel (models with a turbo-supercharging)

10 — the Oil channel (models without turbo-supercharging) 11 — the Identification field (models without turbo-supercharging) b — Width of the top head of a rod B — Width of the lower head of a rod d — the Internal diameter of the plug of the top head of a rod d1 — the Outer diameter of the plug of the top head of a rod D1 — Diameter of an opening of the lower head of a rod L — distance between centers openings of heads of a rod

Distance between centers conrod heads of "L", mm 1	48.7 - 149.3
Width of top "b" and lower "In" heads of a rod, mm	21.48 - 22.00
Diameter of "D1" of the lower head rod, mm	51.600 - 51.614
Admissible ovality and conicity of an opening of the lower head of a rod, mm	0.02
Admissible twisting of a rod on 100 mm of length, mm	0.1
Admissible difference in a deviation from parallelism between heads rod on 100 mm of length of a rod, mm	0.045
Internal diameter of the plug top heads of a rod of "d", mm	28-018 - 28.024
External diameter of the plug, mm	30.575 - 30.600
Diameter under the plug in a verkhneygolovka of a rod of "d1", mm	30.500 - 30.525
Gap of a piston finger in the plug top head of a rod, mm	0.007-0.008
Maximum vystupaniye (Rz) of the plug rod outside, micron	5
Maximum admissible difference of weight of rods,	2

The sizes of openings in the block of cylinders under installation of sleeves, mm

Extraction of a sleeve

Diameter of "D2" under a sleeve in a patch of light of cylinders, mm	9.000 - 90.535
Diameter of "D1" under a sleeve fillet in the block of cylinders, mm	90.55 - 90.65
Diameter "D" under a fillet sleeves in the block of cylinders, mm	92.65 - 92.75
Length of a sleeve of "T", mm	231.0-231.2
Landing depth of a sleeve of "T1", mm	1.0 - 1.2

Sizes of cylinders

A — the Longitudinal direction B — the Cross direction and — the Top point of the course of the top compression ring	b — the Lower dead point with — the Lower point of the course of an oil scraper ring 1, 2, 3 — Points of measurements

Diameter, mm
Nominal	87.0
Dimensional group A	87.000 - 87.006
Dimensional group X	87.007 - 87.012
Dimensional group B	87.013 - 87.018
Admissible limit of the cylinder in longitudinal and cross directions, mm	0.20
Admissible conicity of cylinders new block, mm	0.000 - 0.014
Limit of wear, mm	0.05
Admissible ovality of cylinders, mm	0.07

Sizes of a bent shaft

Diameter of an opening under a bent shaft, mm	62.500 - 62.519
Opening width under a bent shaft at the established inserts, mm	19.979 - 20.000
Admissible ovality and conicity beds of inserts radical bearings of a bent shaft, mm	0.02
Working gap in radical bearings, mm
New	0.03 - 0.05
Maximum permissible	0.08
Axial side play of a bent shaft, mm
New	0.10 - 0.25
Maximum permissible	0.3
Radial beating of a bent shaft, mm	0.020 - 0.065
Nominal inserts of a bent shaft for covers of bearings with a diameter of 58 mm
Repair diameter (color - blue), mm	52
Thickness of an insert, mm	2.255 - 2.260
Repair diameter (color - yellow), mm	54
Thickness of an insert, mm	2.260 - 2.265
Thickness of an insert, mm	2.265 - 2.270
Repair diameter (color - white), mm	57
Thickness of an insert, mm	2.270 - 2.275
Repair diameter (color - purple), mm	58
Thickness of an insert, mm	2.275 - 2.280
Inserts of the 1st repair size of a bent shaft for covers of bearings with a diameter of 57.70 mm
Thickness of an insert, mm	2.37
Inserts of the 2nd repair size of a bent shaft for covers of bearings with a diameter of 57.40 mm
Thickness of an insert, mm	2.50
Inserts of the 3rd repair size of a bent shaft for covers of bearings with a diameter of 57.20 mm
Thickness of an insert, mm	2.62
Inserts of the 4th repair size of a bent shaft for covers of bearings with a diameter of 56.90 mm
Thickness of an insert, mm	2.75

Efforts of tightening of threaded connections, Nanometer

Order of tightening of bolts of a head of the block of cylinders on models with petrol engines

Order of tightening of bolts of a head of the block of cylinders on models with diesel engines

Bolts of a head of cylinders
Petrol models (length to the basis heads no more than 162.7 mm)	55nchm, +90 °, +90 °
S300 TDI to 01.89 g (length to the basis of heads no more than 83.6, 105.6 and 118.6 mm)	25nchm, +40nchm to wait for 10 min., +90 °, +90 °
S300 TDI after 01.89 g (length to the basis heads no more than 82, 104 and 117 mm)	15nchm, +35nchm, +90 ° to wait for 10 min., +90 ° (M8 25nchm)
Bolts of covers of radical bearings
S280, S320 (length to the head basis no more than 63.8 mm)	55nchm, +90 °, -100 °
S420, S500	25nchm, +50nchm
S300 TDI	M11: 55nchm, +90 °, M12: 90nchm
S600	M8: 30nchm, M10: 50nchm
Bolts of covers of conrod bearings
S280, S320 (length to the head basis no more than 52.9 mm)	30+90 °
S420, S500, S600	45nchm, +90 °, -100 °
S300 TDI	40nchm, +90 °, -100 °
Flywheel bolts / driving disk S280, S320, S420 (diameter of not carving part no more than 8.1 mm for a flywheel, 8.0 mm for a driving disk)	30 Nanometer, +90 °
S300 TDI	40nchm, +90 °, -100 °
S500, S600	35nchm, +90 °, -100 °
Coupling basket on a flywheel	25
Crankshaft pulley
S280, S320, S420, S500, S600	400
S300 TDI	200nchm, +90 °
Bolts of asterisks of cam-shafts
S280, S320	Torx: 22, Six-sided: 18, Torx with a fillet: 20 Of Nanometer +90 ° -100 °
S420, S500	18
S300 TDI	25nchm, +90 °
S600	20nchm, +90 °, -100 °
Cam-shaft bed cover
S280, S320, S600	21
S420, S500	12
S300 TDI	25
Cover of rockers of a cam-shaft
S280, S320, S420, S500, S600	9
S300 TDI	10
Candles
S280, S320, S420, S500	25-30
S600	25
S300 TDI	20
Clips of nozzles	30
TNVD flange	20
Nozzle spray to the holder	80
Lambda probe	50-60
Detonation sensor	20
Series M engines	104.94/99
Bolts and nuts of fastening of the inlet pipeline to a head of the block of cylinders	25
Bolts of fastening of a cover of a head of the block of cylinders	10
Bolts of fastening of a cover of a chain of the GRM drive to the block of cylinders
M6	9
M8	21
Bolt of fastening of the tension device to the block of cylinders	75
Bolt of fastening of fittings to a control plunger
1st version	7
2nd version	5 Of Nanometer + 90 °
M20 regulator nut	65
Drain stopper	25
Bolts of fastening of the pallet to the block of cylinders
M6	10
M8	25
M10	40
Oil pipelines to the pallet	10
Asterisk of the oil pump to the pump	32
Bolts of fastening of a cover of the M6 oil pump	10
Oil filter to the block of cylinders	25
Cover of an oil filter	20
The oil pressure sensor to the case of an oil filter	20

Engines of the M119.97/98 series

Bolt of fastening of a cover of a head of the block of cylinders	9
Bolts of fastening of the inlet pipeline	28
Bolt of fastening of the top part of inlet the pipeline to the lower part	25
Exhaust pipe to a final collector	20
Bolts of fastening of a final collector	30
Bolts of fastening of a cover of the case of the thermostat	10
Bolts of fastening of the pump of the cooling system	21

Engines of the M120.980/982 series

Bolt of fastening of the inlet pipeline	28
Bolt of fastening of an intermediate flange	28
Nuts of fastening of a final collector	30
Bolt of fastening of a forward cover of M8	25
GRM drive chain cover to the block of cylinders
M6	9
M8	21
Bolt of fastening of the air pump / arm of the generator	25
Stopper of a natyazhitel of a chain of the GRM drive	40
The case of a natyazhitel of a chain of the GRM drive in a GRM drive chain cover	80
Nut of fastening of a flange to an asterisk	65
Bolt of fastening of fittings to a plunger	5 Of Nanometer + 90 °
Bolt of fastening of a cover of the camshaft	21 °
Bolts of fastening of a maslootrazhatel	9
Bolts of fastening of the pallet to the block of cylinders
M6	10
M8	21
M12	40
Drain stopper of M12	40
Bolt of fastening of a maslootrazhatel to the pallet M12	9
Asterisk of the oil pump	28
Bolts of M6 of fastening of the coupling of the fan and pulley of the pump of the cooling system	10
Bolts of M6 of fastening of the pump of the cooling system	21

Engines of the OM603.971 series

The spring lever on a head of the block of cylinders	21
Bolt of fastening of a tension roller	30
Finger of the tension lever	100
Shock-absorber of the tension device to a head of the block of cylinders	25
Shock-absorber of the tension device to the tension lever	20
Bolts of fastening of a cover of GRM to a head block of cylinders
Bolts of fastening of a cover of a head block of cylinders	10
Bolt of fastening of a cover of a chain of the drive GRM to a head of the block of cylinders	25
Natyazhitel of a GRM drive chain	80
Bolt of M12 of the bearing of a bent shaft	90
Bolts of fastening of the pallet
M6	10
M8	25
Bolt of fastening of the sensor of level of oil	10
Bolt of fastening of an asterisk of the oil pump	32
Nut of fastening of a cover of the oil pump	25
Bolt of fastening of the case of an oil filter to the block of cylinders	25
Bolt of fastening of a pulley of the pump of the cooling system	15
Bolt of fastening of the pump of the cooling system to the case	10
Bolt of fastening of a pump housing of the cooling system to the block of cylinders	10

Engines of the OM606.961 series

Bolt of fastening of a cover of a head of the block of cylinders	10
Carving ring of the precamera in a head of the block of cylinders	130
Bolt of fastening of the case distributive shaft to a head of the block of cylinders	15
Bolt of fastening of a cover of the camshaft	15
Bolt of fastening of a cover of a chain of the GRM drive to a head of the block of cylinders	25
Bolt of fastening of a cover of a chain of the GRM drive to the block of cylinders	10
Natyazhitel of a GRM drive chain	80
Back nave	320
Forward support to the holder	35
Back support to the holder (TDI)	115
The holder of a support to a fist
Forward wheels	115
Back wheels
To 07.93 g	115
After 08.93 g	50
Nuts of tips of steering drafts
S280, S320, S300 TDI	50
S420, S500, S600	55
Wheels
S280, S320, S420, S500, S600	150
S300 TD	I 110